METHOD OF MANUFACTURING SPRAY-ON FOOTWEAR
First Claim
1. A method of constructing footwear comprising:
- providing three dimensional last data corresponding to at least one of an aesthetic footwear design, a dimension of a sample foot and a surface contour of the sample foot;
printing a three dimensional last utilizing the three dimensional last data, the three dimensional last including a plurality of exterior footwear surfaces;
providing a source of spray-on fabric, the spray-on fabric comprising a plurality of fibers that are combined with a polymer and a solvent, the solvent adapted to enable the spray-on fabric to be dispensed from the source in at least one of a liquid form and a semi-liquid form;
spraying the spray-on fabric onto the plurality of exterior footwear surfaces of the three dimensional last;
allowing the spray-on fabric to cure on the three dimensional last to form a flexible non-woven first fabric upper, the first fabric upper having a thickness extending from a first upper exterior to a first upper interior, the first upper interior being adjacent the three dimensional last;
removing the first fabric upper from the three dimensional last;
turning the first fabric upper inside out so that the first upper exterior becomes a second upper interior, and the first upper interior becomes a second upper exterior, the second upper exterior having an upper bottom; and
joining a sole to the upper bottom, whereby a finished footwear is produced corresponding to at least one of the sample foot and aesthetic footwear design.
2 Assignments
0 Petitions
Accused Products
Abstract
A method is provided for making footwear utilizing a spray-on material. The method can include spraying a spray-on fabric onto surfaces of a three dimensional last. The last can be produced using additive manufacturing techniques, such as 3D printing, based on data corresponding to dimensions and contours of a consumer'"'"'s foot, and/or preselected aesthetic footwear designs. The spray-on fabric is sprayed onto the surfaces of the last and allowed to cure to form a flexible, non-woven fabric upper. The upper can be removed from the last and turned inside out. With the upper turned inside out, a sole can be joined to the fabric upper to form the footwear.
-
Citations
20 Claims
-
1. A method of constructing footwear comprising:
-
providing three dimensional last data corresponding to at least one of an aesthetic footwear design, a dimension of a sample foot and a surface contour of the sample foot; printing a three dimensional last utilizing the three dimensional last data, the three dimensional last including a plurality of exterior footwear surfaces; providing a source of spray-on fabric, the spray-on fabric comprising a plurality of fibers that are combined with a polymer and a solvent, the solvent adapted to enable the spray-on fabric to be dispensed from the source in at least one of a liquid form and a semi-liquid form; spraying the spray-on fabric onto the plurality of exterior footwear surfaces of the three dimensional last; allowing the spray-on fabric to cure on the three dimensional last to form a flexible non-woven first fabric upper, the first fabric upper having a thickness extending from a first upper exterior to a first upper interior, the first upper interior being adjacent the three dimensional last; removing the first fabric upper from the three dimensional last; turning the first fabric upper inside out so that the first upper exterior becomes a second upper interior, and the first upper interior becomes a second upper exterior, the second upper exterior having an upper bottom; and joining a sole to the upper bottom, whereby a finished footwear is produced corresponding to at least one of the sample foot and aesthetic footwear design. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
-
-
10. A method of constructing footwear comprising:
-
spraying a first spray-on fabric onto a plurality of exterior footwear surfaces of a three dimensional last, the three dimensional footwear being in the form of a human foot; allowing the first spray-on fabric to cure on the three dimensional last to form a flexible non-woven first fabric upper, the first fabric upper having a thickness extending from a first upper exterior to a first upper interior, the first upper interior being adjacent the three dimensional last; removing the first fabric upper from the three dimensional last; turning the first fabric upper inside out so that the first upper exterior becomes a second upper interior, and the first upper interior becomes a second upper exterior; and joining a sole to the first fabric upper while the first fabric upper is turned inside out, whereby a finished footwear is produced corresponding to at least one of the sample foot and aesthetic footwear design. - View Dependent Claims (11, 12, 13, 14, 15, 16, 17, 18, 19)
-
-
20. A method of constructing footwear comprising:
-
spraying a spray-on fabric onto a plurality of exterior footwear surfaces of a first three dimensional last in the form of a human foot; allowing the spray-on fabric to cure to form a flexible non-woven fabric upper; removing the fabric upper from the first three dimensional last; turning the fabric upper inside out; placing the fabric upper on a second three dimensional last while the fabric upper is turned inside out; and joining a sole to the fabric upper while the fabric upper is turned inside out and disposed on the second three dimensional last.
-
Specification